Process of preparing a catalyst containing activated isomerization sites

ABSTRACT

Isomerization is effected at improved conversion and selectivity by use of a 0.5 w %-2.5 w % platinum-palladium group metal on hydrogen mordenite catalyst, the catalyst having been calcined at 1200° F.-1500° F. prior to use whereby it acquires activated sites not present in mordenite calcined at lower temperature.

This is a division of application Ser. No. 342,546 filed Jan. 25, 1982,which issued on Dec. 18, 1984 as U.S. Pat. No. 4,489,216.

FIELD OF THE INVENTION

This invention relates to hydrocarbon conversion. More specifically itrelates to the isomerization of hydrocarbons.

BACKGROUND OF THE INVENTION

As is well known to those skilled in the art, hydrocarbons may beisomerized to form more desired products in the presence of variouscatalysts typified by mordenite catalysts. Illustrative of prior artshowing mordenite catalysts and their use in hydrocarbon processing maybe noted in U.S. Pat. Nos. 3,507,931, 3,190,939, 3,539,498, 3,831,597,3,925,503, Brit. No. 1,088,933 etc.

In isomerization processes, a prinicpal problem is the attainment ofhigh yield and selectively of desired isomates; and minimization ofcompeting reactions is a desiderata. A principal undesired competingreaction is cracking; and a common measure of effectivity of anisomerization catalyst is its ability to maximize isomerization whileminimizing cracking.

It is an object of this invention to provide a process forisomerization. Other objects will be apparent to those skilled in theart.

STATEMENT OF THE INVENTION

In accordance with certain of its aspects, this invention is directed toa method of preparing a catalyst which comprises loading a hydrogenmordenite, having a silica-to-alumina mole ratio of 10-20:1, with ametal of the platinum-palladium group thereby forming a loaded hydrogenmordenite; calcining said loaded hydrogen mordenite at 1200°-1500° F.thereby forming a calcined hydrogen mordenite containing activatedisomerization sites; and recovering said calcined hydrogen mordenitecontaining activated isomerization sites.

DESCRIPTION OF THE INVENTION

The charge composition which may be used in practice of the invention isa particular form of crystalline alumino-silicate known as mordenite.Although mordenite is naturally occurring in the sodium form, syntheticmordenites have become commercially available and are extremely usefulin the process of our invention. In its sodium form, mordenite usuallyhas minimal catalytic activity and must therefore be converted to thehydrogen or decationized form before it finds utility in catalyticprocesses.

Mordenite structures are characterized by parallel sorption channels ofuniform cross-section. The sorption channels are parallel to the C-axisof the crystal and are elliptical in cross-section. The sorptionchannels of sodium mordenite, based on crystallographic studies, havebeen reported as having a minor diameter of 6.7 A., a major diameter of7.0 A., and a free diameter of 6.6 A.; the hydrogen form of mordenite isbelieved to have a slightly larger free diameter.

Although mordenite occurs in nature, synthetic mordenites arecommercially available from the Norton Company under the trade nameZeolon. Thes mordenites have a chemical composition on a unit cellbasis, of

    M.sub.8/n ·Al.sub.8 Si.sub.40 ·O.sub.96 ·24H.sub.2 O

where M may be sodium, hydrogen or some other exchangeable cation and nis the valence of the cation. The high ratio of silica to alumina of10:1 in the synthetic mordenite permits complete acid exchange to astable hydrogen form and imparts excellent chemical and thermalstability. The effective working diameter of the channels in hydrogenmordenite (prepared by acid treating synthetic sodium mordenite),marketed under the trade name Zeolon H, appears to be in the range of7.6 to 8.5 A. as indicated by adsorption of aromatic hydrocarbons.

Structurally mordenite is significantly distinguishable from otherzeolites. Mordenite's tube-like gas sorption chambers have but twoopenings thru which hydrocarbon molecules can pass. In contrast thesorption chamber in Type A zeolite has six windows or pore openingsthrough which hydrocarbons can pass. The sorption chambers in X and Yzeolites have four windows.

The sodium form of mordenite is not effective for isomerizationregardless of whether the temperature is within the range unusuallyemployed to effect paraffin isomerization and regardless of catalystadditions. However, the hydrogen form of synthetic mordenite having asodium content of less than 5 weight percent is exceptionally effectivefor converting paraffins to their isomers. Decationized mordenite, i.e.mordenite in the hydrogen form, may be produced by the exchange of thesodium in the mordenite with ammonium ions followed by heating orcalcining to drive off ammonia.

An extremely effective method of producing the decationized mordenite isby acid treatment of mordenite charge which has been calcined attypically 1200° F.-1500° F., say 1292° F. for 1-12 hours preferably 2hours. In addition to decationizing the calcined mordenite, acidtreatment may also remove some of the aluminum from the zeoliticstructure, thereby increasing the relative proportion of silica toalumina in the zeolite. In its sodium form, both natural and syntheticmordenite have a mole ratio of silica to alumina of about 10 to 1.Hydrogen mordenite also has a silica to alumina mole ratio of about 10to 1, but treating the sodium mordenite with dilute acid to produce thedecationized form may remove aluminium sufficiently to increase thesilica to alumina ratio slightly above 10 to 1.

The acid leaching used to produce the mordenite catalysts employed inthe process of this invention must be severe enough to substantiallyincrease the silica to alumina mole ratio of the mordenite to aboveabout 10:1. However, the acid leaching must not be so severe as todestroy the crystalline structure of the mordenite. Further, littleimprovement has been observed in our isomerization process where thesilica to alumina ratio of the mordenite is greater than about 50:1.

Consequently, as a practical limit the acid leaching should be severeenough to produce a mordenite having a silica to alumina ratio between10:1 and 20:1.

Acid leaching of calcined mordenite may be suitably effected withmineral acids which will selectively remove aluminum without destroyingthe zeolitic crystalline structure, for example, hydrochloric orsulfuric acid. Boiling dilute hydrochloric acid is extremely effectivein removing the aluminum.

Although we have described an acid leaching technique for preparing themordenite catalysts used in our process, hydrogen mordenites havingsilica to alumina mole ratio between about 10:1 and about 20:1 preparedby other methods may also be employed in our process.

The hydrogen mordenite catalyst support so prepared is preferablywater-washed and calcined in air at 1000° F.-1500° F., say 1300° F., fortypically 15 hours.

Whether or not the hydrogen mordenite is prepared by exchange of NH₄ ⁺for Na+ or by leaching with acid such as hydrochloric acid, prior artteaching indicates that the acid mordenite should not be calcined totemperature above about 1000° F. because the sintering which occurs atthe higher temperature is said to destroy the catalytic activity.Accepted prior art belief has generally been to the effect thatcalcination above 1000° F. may sinter catalyst metals and destroy activecatalyst sites.

The catalyst support, in NH₄ ⁺ or more preferably in H⁺ form, soobtained is loaded with a metal of the platinum-palladium group:platinum, iridium, osmium, palladium, rhodium, or ruthenium. Preferredmetals include platinum and palladium and more preferably palladium. Aloading of 0.1 w %-10 w %, say 2 w % palladium may be employed.

Catalyst containing metal-on-hydrogen mordenite is obtained by immersingthe catalyst support in preferably aqueous solutions containing solublesalts (such as palladium nitrate) of the metals--preferably in severalsteps after each of which the loaded catalyst composition may be driedat 212° F.-1000° F., preferably raising the temperature in steps over aneight hour period to 1000° F.

The metal is distributed substantially as 50-500 A crystals over thesurface of the mordenite crystals.

When the final catalyst composition is formulated, it may be dried at212° F.-1000° F., preferably raising the temperature in steps over aneight hour period to 1000° F. before calcining.

It is a feature of the process of this invention that the final loadedcatalyst composition must have been calcined at 1200° F.-1500° F.,preferably 1250° F.-1350° F., say 1300° F. for 2-24, say 15 hours priorto use in isomerization.

It is for example possible to carry out this high temperaturecalcination in the following manner:

(i) calcine the catalyst support, prior to loading with metal, at 1200°F.-1500° F., say 1300° F. for 15 hours followed by calcination of theloaded support at temperature of 1200° F.-1500° F. for 2-24 hours, say15 hours, or more preferably:

(ii) calcine the catalyst support prior to loading with metal, at atemperature below 1200° F.-1500° F., say typically 1000° F.-1200° F.,say 1000° F. for 1-15 hours, say 8 hours followed by calcination of theloaded support at 1200° F.-1500° F., say 1300° F. for typically 2-24hours, say 15 hours.

Regardless of which of these techniques is used to prepare the finalcatalyst composition, the mordenite, will have been modified oractivated. It is found that heating the catalyst to 1200° F.-1500° F.,after it has been loaded with metals from aqueous solution, converts theBronsted sites (formed during contact with aqueous media) to desiredactive sites.

Specifically it appears that the Bronsted acid sites (formed duringdeposition of metals from aqueous media) which are substantiallyuntouched at temperatures below about 1200° F. are converted, attemperatures above about 1200° F., to Lewis acid sites which areactivated sites for various reactions including isomerization,trans-alkylation, disproportionation, etc. Calcining the catalystcomposition at 1200° F.-1500° F. after the composition has been exposedto water for the last time, permits attainment of compositioncharacterized by presence of active isomerization sites. Specificallyits found that the number of desired Bronsted sites in the mordenitewhich has been calcined to 1200° F.-1500° F. is less than about 50% ofthe number found in mordenite which has been calcined at say 1000° F. Infact calcining at the upper portion of the 1200° F.-1500° F. rangereduces the Bronsted sites to a minimum. It is found that the desiredLewis acid sites so formed are retained if the catalyst composition bemaintained (and used) under substantially anhydrous conditions, as waterwill regenerate the Bronsted sites.

It is also unexpectedly found that calcining the mordenite catalysts ofthis invention under the noted conditions desirably decreases thecracking activity of the catalyst composition when isomerization iscarried out at 400° F.-500° F.

It is a feature of this invention that this increased isomerizationactivity is found in acid mordenites having a silica to alumina ratiowhich is above about 10:1. As the ratio increases to about 20:1, themaximum isomerization activity is observed (for 1300° F. calcination ofloaded mordenite) and as the ratio increases to about 60:1, the degreeof isomerization drops to a level at which it is no longer desirable. Itappears that it is desirable to operate in the range of 10-20:1.

It may be noted however that the preferred ratio may vary depending onthe desiderata. By way of illustration, it is possible by using acatalyst having a ratio of 10:1, calcined at 1300° F. after depositionof metal, to obtain an isomate yield of 18% with no cracked product. Useof a 20:1 mordenite, calcined at 1300° F., may double the isomate yieldto 36%, but undesirably increases the yield of cracked product to 13%.Generally it is observed that use of lower ratios, preferably 10:1,gives higher ratio of isomate to cracked product; while higher ratios upto 20:1 give more isomate but at lower ratio of isomate to crackedproduct. Use of silica to alumina ratios as high as 60:1 generally giveslower yield of isomate and cracked product and lower ratio of isomate tocracked product.

Expressed differently, the selectivity and conversion to desired isomateis highest in the range of ratios of 10-20:1.

A preferred catalyst to be employed in practice of the process of thisinvention may be a 2 w % palladium-on-hydrogen mordenite (20:1 weightratio of silica-to-alumina) which has been calcined at 1300° F. afterbeing loaded with palladium.

The hydrocarbons which may be isomerized by the process of thisinvention may include paraffinic or olefinic hydrocarbons typicallyhaving 4-20, preferably 4-12, say 8 carbon atoms; aromatic hydrocarbonstypified by xylenes; olefins typically having 4-20, preferably 4-12, say8 carbon atoms; etc. The preferred charge stock may include paraffinichydrocarbons typified by n-butane, n-hexane, n-heptane, n-octane,n-decane, n-dodecane, etc.

The instant catalyst may find use in isomerization processes wherein theposition of the double bond is changed as typified by the conversion ofbutene-1 to butene-2. It may also find use in disproportionationprocesses such as the conversion of toluene to benzene and xylene or intransalkylation processes such as the reaction of benzene and xylene toprepare toluene.

Prior to use of the calcined catalyst composition, it is preferred toprecondition the composition by heating, in a flowing stream ofhydrogen, to 450° F.-1000° F., preferably 500° F.-675° F., say 550° F.for 3-24 hours, preferably 10-20 hours, say 15 hours--followed bymaintaining at 700° F.-800° F., say 780° F. for 1-2 hours, say 2 hours.Pretreating, like isomerization, is preferably carried out undersubstantially anhydrous conditions.

Isomerization in accordance with the process of this invention may becarried out by passing the charge isomerizable hydrocarbon into contactwith the preconditioned catalyst in the presence of hydrogen, at thefollowing conditions:

                  TABLE                                                           ______________________________________                                        Condition  Broad        Preferred Typical                                     ______________________________________                                        Temperature °F.                                                                   400-500      400-450   435                                         Pressure psig                                                                             0-100        0-50     0                                           LHSV       0.1-20       0.1-2     1                                           Hydrogen rate                                                                            1000-5000    1500-2500 2300                                        SCFB                                                                          ______________________________________                                    

The catalyst may be in the form of granules, e.g. 10 to 25 mesh TylerStandard Screen Scale, and preferably is in the form of pellets orextrusions having a diameter of about 1/16 inch. The reaction issuitably carried out over a fixed bed of catalyst with the hydrogen andfeedstock passing downwardly through the catalyst bed. Unreactedhydrogen may be separated from the effluent stream from the catalyst bedand recycled to the process.

Operating temperature and catalyst activity are correlated with spacevelocity to give reasonably rapid processing of the feedstock atcatalyst deactivation rates which insure maximum on-stream time of thecatalyst between periods of regeneration.

As the catalyst ages, its activity for the desired reaction tends toslowly diminish. The catalyst may be maintained at or periodicallybrought back to approximately its initial level of activity byincreasing the operating temperature as the catalyst ages.

The stream leaving the isomerization operation may be characterized byhigh conversion and by high selectivity to desired products. In theisomerization of normal paraffins, for example, operation underpreferred conditions leads to conversions of 40%-62%, say 50%.Selectivity to desired isomate may be 40%-100%, say 75%. Susceptibilityto cracking increases with hydrocarbon chain length. Selectivity ofbetter than 95% is attained during isomerization of normal heptane. Inthe case of normal dodecane, selectivity may be as low as 73%. The ratioof yield of undesirable cracked product to isomate yield may be 0-3:1.

It may be possible to effect disproportionation of disproportionablehydrocarbons by the process of this invention. Typical of suchhydrocarbons are aromatic hydrocarbons such as toluene (which producebenzene and xylenes); olefines such as butene-1 (which produce butadieneand butanes); etc.

Disproportionation conditions may include:

                  TABLE                                                           ______________________________________                                        Condition    Broad       Preferred                                                                              Typical                                     ______________________________________                                        Temperature °F.                                                                      600-1100   600-900  750                                         Pressure psig                                                                                0-1500     0-500   250                                         LHSV         0.1-20      0.5-2     1                                          ______________________________________                                    

It may also be possible to effect transalkylation of transalkylatablehydrocarbons by the process of this invention. Typical of such reactionsmay be (i) the reaction of benzene and xylenes to prepare toluene; (ii)the reaction of toluene and higher alkylbenzenes to prepare xylenes;etc.

Transalkylation conditions may include:

                  TABLE                                                           ______________________________________                                        Condition    Broad       Preferred                                                                              Typical                                     ______________________________________                                        Temperature °F.                                                                     750-850     750-800  750                                         Pressure psig                                                                                0-3000     0-500   250                                         LHSV         0.2-1.0     0.5-1    1.0                                         ______________________________________                                    

DESCRIPTION OF PREFERRED EMBODIMENTS

Practice of the process of this invention may be apparent to thoseskilled in the art from inspection of the following wherein, aselsewhere in this application, all parts are parts by weight unlessotherwise stated.

EXAMPLE I

In the series of runs which make up this Example, three differenthydrogen mordenites are employed: viz, those having a weight ratio ofsilica-to-alumina of 10:1, of 20:1, and of 60:1. Each mordenite sampleis loaded with 2 w % palladium from an aqueous solution of palladiumchloride and then dried at 212° F. for 15 hours. The loaded mordenite isthen calcined at the temperature indicated in the following table for15-19 hours. It is then preconditioned in hydrogen at a rate of 50 ccper hour per cc of catalyst at 300° F./l atm for 15-19 hours followed bya period of 2 hours at 780° F.

Isomerization of charge n-dodecane is effected at 400° F./l atmospherepressure and 1 LHSV. Hydrogen flow rate is 50 volumes per minute volumeof catalyst. Runs are carried out for five hours and the following tablesets forth the results in terms of yield of isomate and yield of crackedproduct. By way of illustration, the entry 36/13 in the Table indicatesthat when the catalyst composition is 2 w % palladium-on-hydrogenmordenite (the loaded catalyst having been calcined at 1300° F.), theproduct of reaction contains 36 w % of isomate and 13 w % of crackedproducts.

                  TABLE                                                           ______________________________________                                        Calcination                                                                             SiO.sub.2 :Al.sub.2 O.sub.3 Ratio of Mordenite                      Temp. °F.                                                                        10:1          20:1     60:1                                         ______________________________________                                        1480                             1/0                                          1400      7/1           17/4                                                  1300      18/0          36/13    2/9                                          1200      12/16          9/26    1/3                                          1000      0/6            0/100   3/7                                          Uncalcined                                                                               0/100         5/24    14/10                                        ______________________________________                                         Results in terms of isomate w % yield/crackate w % yield                 

From this Table, it will be apparent to those skilled in the art thatbest yields of isomerized product are attained when using mordenitehaving a silica-to-alumina ratio of 10-20:1 which has been calcined at acalcination temperature of 1200° F.-1500° F.; the product contains asmuch as 36 w % of isomerized dodecanes. It will be noted that use of a 2w % palladium-on-mordenite (silica-to-alumina ratio of 10:1) which hasbeen activated at 1300° F. gives product containing a substantialportion (18 w %) of isomerized product and which is substantially freeof cracked product.

Generally isomate yield is poor and cracking bothersome when thecatalyst is either uncalcined or is calcined at 1000° F. Isomate yieldimproves (as does Selectivity) with increasing calcination temperatureup to about 1300° F. A "center of gravity" calculation indicates thatabout 1313° F. is optimum for activating the 20:1 ratio mordenite, while1286° F. appears to be optimum for the 10:1 mordenite. It should benoted that the 60:1 ratio mordenite could not be thermally activated forisomerization as evidenced by low yield of dodecane isomate.

EXAMPLES II-VI

In these Examples, 2 w % palladium-on-mordenite catalysts are preparedon mordenites of various silica-to-alumina ratios. Thepalladium-on-mordenite catalyst is either (i) uncalcined i.e. merelydried at 212° F. for 15 hours prior to hydrogen preconditioning, incontrol Examples III*-VI* or (ii) calcined at 1300° F., in experimentalExample II.

Charge composition and reaction conditions are identical to those ofExample I except that isomerization of Example V is carried out at 410°F.

The following Table lists (i) the isomate obtained as weight % of thecharge n-dodecane, (ii) the cracked product obtained, both liquid andgas, on the same basis and (iii) the Deactivation Time (hours). Thelatter is determined by the intercept with the log t axis of a plot ofconversion to isomate as a function of log t (i.e. wherein time is inhours).

                  TABLE                                                           ______________________________________                                                                  Crackate  Deactivation                              Example                                                                              Ratio    Isomate   Gas   Liquid                                                                              Time hrs                                ______________________________________                                        II     20       36         9    4     163                                     III*   20       5         21    3     13                                      IV*    10       0         100   0      0                                      V*     10       9         10    4     14                                      VI*    60       14         7    3     13                                      ______________________________________                                         *Control                                                                      Deactivation time is the time (hours) required to lose isomerization          activity.                                                                

From inspection of the Table, it is apparent that the experimentalcatalyst of Example II (calcined at 1300° F.) has a deactivation time(163 hours) which is 12+ times that of the best (13-14 hours) of thecontrol Examples. It is also apparent that the run of Example IIproduced almost three times as much isomate as did the runs of the bestof the other Examples. Other conclusions will be apparent to thoseskilled in the art.

EXAMPLES VII-VIII*

In this pair of comparative examples, experimental Example VII, apreferred embodiment of the process of this invention, utilizes a 2 w %palladium-on-mordenite (silica-to-alumina ratio of 20:1) which wasprepared as in Example I. Calcination temperature is 1300° F. afterpalladium loading. Preconditioning and reaction are as in Example I.Charge hydrocarbon is n-heptane.

As control Example VIII*, the results set forth in Table 10 of BritishPat. No. 1,088,933 are set forth. The results of the British patent,expressed in mole %, are converted to weight %.

The Table below sets forth the content of the product from isomerizationand the Conversion and Selectivity.

                  TABLE                                                           ______________________________________                                        Hydrocarbon         Example                                                   Product             VII    VIII*                                              ______________________________________                                        Unconverted heptane 37.6   45                                                 Dimethyl pentane    10.2   1.1                                                2-methyl hexane     26.1   9.9                                                3-methyl hexane     22.4   11.-                                               3-ethyl pentane     2.4    0                                                  Cracked Product     1.3    33                                                 Conversion w %      62.4   55                                                 Selectivity w %     98     40                                                 ______________________________________                                    

From the above Table, it will be observed that the Conversion andSelectivity of the experimental Example VII are substantially superiorto those of control Example VIII*. The amount of cracked product of theexperimental (1.3%) is substantially smaller than that of the controlexample (33%). Other conclusions will be apparent to those skilled inthe art.

EXAMPLE IX

In this example, transalkylation may be effected by use of the samepreferred catalyst as used in Example VII. Charge contains benzene andxylenes in mole ratio of 1.1 moles of xylene per mole of benzene, LHSVis 1.0. Reaction is carried out at 750° F. and 250 psig in the presenceof hydrogen in amount of 2300 SCFB. Product transalkylate is found tocontain toluene.

EXAMPLE X

In this example, disproportionation may be effected by use of the samepreferred catalyst as used in Example VII. Charge is toluene at LHSV of1.0. Reaction is carried out at 750° F. and 250 psig in the presence ofhydrogen in amount of 2300 SCFB. Product disproportionate is found tocontain benzene and xylenes.

Although this invention has been illustrated by reference to specificembodiments, it will be apparent to those skilled in the art thatvarious changes and modifications may be made which clearly fall withinthe scope of this invention.

I claim:
 1. The method which comprisesloading a hydrogen mordenitehaving a silica-to-alumina mole ratio of 10-20:1, with a metal of theplatinum-palladium group thereby forming a loaded hydrogen mordenite;calcining said loaded hydrogen mordenite at 1200° F.-1500° F. therebyforming a loaded calcined hydrogen mordenite containing activatedisomerization sites; and recovering said loaded calcined hydrogenmordenite containing activated isomerization sites.
 2. The method ofclaim 1 wherein said calcination is carried out at 1250° F.-1350° F. 3.The method of claim 1 wherein said calcination is carried out at about1300° F.
 4. The method of claim 1 wherein said metal is palladium. 5.The method of claim 1 wherein said metal is palladium in amount of 0.5 w%-2 w %.
 6. The method which comprisesloading a hydrogen mordenitehaving a silica-to-alumina mole ratio of 10-20:1, with 0.5 w %-2.5 w %palladium thereby forming a palladium-on-hydrogen mordenite; calciningsaid palladium-on-hydrogen mordenite at 1200° F.-1500° F. therebyforming a calcined palladium-on-hydrogen mordenite containing activatedisomerization sites; and recovering said calcined palladium-on-hydrogenmordenite containing activated isomerization sites.
 7. The method whichcomprisesloading a hydrogen mordenite having a silica-to-alumina moleratio of 10-20:1 with 0.5 w %-2.5 w % platinum thereby forming apalladium-on-hydrogen mordenite; calcining the platinum-on-hydrogenmordenite at 1200° F.-1500° F. thereby forming a calcinedplatinum-on-hydrogen mordenite containing activated isomerization sites;and recovering said calcined platinum-on-hydrogen mordenite containingactivated isomerization sites.
 8. The method of claim 1 wherein saidcalcination temperature is 1250° F.-1350° F.
 9. The method of claim 1wherein the hydrogen mordenite catalyst is in the NH₄ + form.
 10. Acatalyst composition prepared by the method which comprisesloading ahydrogen mordenite having a silica-to-alumina mole ratio of 10-20:1,with a metal of the platinum palladium group thereby forming a loadedhydrogen mordenite; calcining said loaded hydrogen mordenite at 1200°F.-1500° F. thereby forming a loaded calcined hydrogen mordenitecontaining activated isomerization sites; and recovering said loadedcalcined hydrogen mordenite containing activated isomerization sites.11. A catalyst composition as claimed in claim 10 wherein said metal ispalladium.
 12. A catalyst composition as claimed in claim 10 whereinsaid metal is palladium in amount of 0.5-2.5 w%.